Woven fabric



Patented Feb. 22, 1938 UNITED STATES PATENT .OFFICE- 1 Claim.

This invention relates to mechanical fabrics, suitable for various uses, and consists in a woven felt of unique character and in the method of its production.

In the accompanying drawing Fig. I is a diagrammatic view in cross-section and to magnified scale of the fabric in which andl in the production of which the invention is realized; Fig. II is a View of a tennis ball in elevation, covered with the fabric of the invention; Fig. IIa is a fragmentary view in section of such a ball; Fig. III is a diagram illustrating the relation of the Warp and weft threads in successive picks of a Weave that may be employed in the practice of the invention; Fig. IV is a diagrammatic showing of the courses of the woven threads in each complete repetition of the design of the weave of Fig.' III; Fig. V is a diagram of the pattern of the Weave of Figs. III and IV; Figs. VI, VII, and VIII are illustrations of like character, and corresponding to Figs. III, IV, and V, respectively, of a weave of another pattern that may be employed.

The first feature of my invention is that it concerns a wool fabric, woven with floats; that is to say, a weave in which are found warp (or weft) threads that pass over three or more weft (or Warp) threads between successive tyings-in or interweaving with the weft (or warp) threads. 30l Such weaves are not in and of themselves new; they are employed in making fabrics for clothing and for other purposes. 'I'hey never, however, have been employed in making mechanical fabrics; they never have been subjected to the further treatment to which I subject them; and it is in consequence of such further treatment that a fabric of unique characteristics is produced-a fabric that in the mechanical iield is without parallel.

In Fig. I of the accompanying drawing the warp and Woof strands 2I and 22 of a woven felt are diagrammatically indicated, and a body of felted pile 23 is indicated, developed upon one side of the fabric. istics is the object of the invention.l

In illustration of fabrics woven with floats, I have shown two particular weavesnot as an exhaustive showing of such fabrics, but by way of example. The weave of Figs. III-#V is of a class known as Sateen weaves; that of Figs. VI- VIII is of a class known as velveteen weaves.

The particular pattern of Figs. III-V involves eight Warp threads, and is completed in eight picks; in neither of these two'particulars, however, is the production of a Sateen weave or the practice of the invention limited. It is characteristic of the Sateen weave that each weft thread (or, alternatively, each warp thread), after passing under a Warp thread (or, alternatively, a weft thread) shall passrover the three (or more) An article of such characternext succeeding warp threads (or, alternatively, the three, or more next succeeding weft threads) before again passing under another warp thread (or, alternatively, another weft thread). The particular warp (or weft) threads beneath which the weft (or warp) threads pass are'varied from pick to pick in the succession of weft (or warp) threads, as the design develops. 'Ihis passing of the weft (or warp) thread over three` or-more successive warp (or weft) threads develops 'a float upon one side of the woven cloth; and it is the cat that gives to the woven felt the characteristic proper to the attainment of this invention.

Referring in more minute detail to the sateen"v pattern of Figs. III-V,'the warp threads are in Figs. III and IV indicated diagrammatically by the dots I, 2, 3 8; and the weft threads by the lines I0, II, I2 I1. The weft thread Ill of the first pick passes over warp'threads I, 2,'

3, 4, 5; under warp thread 6; `and then over warp threads 1, 8. The weft thread II passes over warp threads I, 2; under Warp threadA 3; and then over warp threads 4, 5, 6, 1, 8, and so on. lThe warp threads thus successively under-'run by tain of the weft (or warp) threads are wovenin normal manner with the warp .(or. weft) threads, and between successive normally woven weft (or warp) threads other threads are interposed that have the characteristic of the threads of the Sateen weave already described: they form;

floats upon one side of the woven cloth. In'more precise parlance the normally woven threads are termed the weft threads and the others the floats. i

In Figs. VI-VIII a velveteen pattern is shown that involves eight warp threads, numbered I, 2, 3 8, as before, and ten picks, Whose successive threads are numbered Ill, II, I2 I9. And again the particular numbers, and the particular combinations of normally woven threads and floats may be varied, within Athe knowledge of the weaver. In this instance threads IB and I5 are woven normally with the warp threads I, 2, 3 8; weft thread II passes beneathr warp thread I and then over all the succeeding warp threads; thread I2 passes over warp threads I and 2, under thread 3, and over the rest; thread I3 passes beneath warpthread 5 only; thread I4 beneath thread 'I only; thread I6 beneath thread 2; Il beneath 4;v I8 beneath 6; and I9 beneath 8. 'I'hus the pattern of Fig. VIII is developed. And, again, as shown in Fig. VII, a relatively heavy nap is developed on one side of the woven cloth. In Fig. VII two threads pass under each warp thread- I5 and Il, IIJ and I6, I5 and I2, I0 and II, I5 and I3, I0 and I8, I5 and I4, I0 and I9.

'I'he art of the weaver is available to afford weaves in which floats are developed upon the woven cloth. The illustrations will suffice to indicate all that is essential: namely, a woven cloth upon one side of which floats afford a heavier nap than upon the other side.

Wool fabrics woven with floats have heretofore been subjected to a fulling operation of relatively short duration and of relatively small effect, and thereafter have been napped or teased.

Inr the practice of this invention the order of the steps is reversed: the newly woven fabric is first teased, and the teasing (applied to the floatbearing surface only) is carried to greater degree than is usual in the teasing (after fulling) of fabrics intended for clothing, with the consequence and effectv that a deep pile is produced upon the float-bearing face of the fabric; and then the so teased fabric is fulled. Furthermore, the fulling is continued for a much longer period than in the fulling of fabric for clothing; and, both because of the preceding heavy teasing and because of the long continuance of the fulling step, an effect different in kind is gained. The fulling of unteased fabrics forA clothing is continuedfor a period of from twenty minutes to Ihalf an hour; the fulling of the heavily teased fabric'in the practice of this invention is continued for a period of from two and a half to four hours.' In consequence, not only is the fabric shrunk to such degree that it lacks pliancy requisite to usefulness in clothing, but it is felted to such degree as to render it suitable for new uses.

Fulling consists in 'subjecting the fabric to heat, moisture, and'pressure. 'Ihe moisture is applied in the form of soap of the consistency of jelly,

or thinner. After fulling, the fabric of the inventionis washed, to carry away the soap and mechanical dirt. 'Ihe fabric then is dried and sheared lightly. In the fulling step the shrinkage is controlled, to afford a finished fabric of the width and weight desired.

The product of the operations described is a relatively stiff fabric with a heavy pile upon one surface, felted to such degree that the individuality of the component threads is lost, and with an opposite surface that is relatively smooth and firm. This fabric comprises a ground web and a pile of wool yarn; it has floats upon one side only; on the float-bearing side a stiff felt is formed that contains more than half of the total body of wool; the opposite side is substantially free of felt. 'Ihis fabric is of superior utility for mechanical uses, as distinguished from use in clothing and blankets. One such use has been indicated-covering for tennis balls. Other uses are facings for polishing pads and rolls, cushions for piano actions, etc.

Tennis balls must be manufactured with greatest uniformity and with very close correspondence to standard figures in physical characteristics, particularly in the matters o-f size, weight, and resilience. And it is of importance and value that the ball shall be durable and shall maintain its integrity and its essential characteristics in fullest measure under prolonged use.

The nap or wooliness of the felt cover of a iceable-at least not in the skillful playing of the game.

I have discovered that, if the fabric provided for the covering of tennis balls be formed as herein described, a coarser wool may be used with advantage than that commonly used for tennis-ball covers. I have discovered that, if the fabric be applied to the ball with the relatively smooth and napless surface in contact with the rubber and the opposite nap-bearing surface outward, two characteristics are made useful in fullest degree. First, the nap that is developed upon one surface alone is a heavier napthan that ordinarily developed equally upon the two surfaces; and, `in consequence, the finished ball has a heavier and more durable nap upon its exposed outer surface, and has, in consequence, greater durability in tournament play.

Second, the inner surface of the cloth, upo which little or no nap is developed, but which is relatively firm and smooth, is susceptible to'.

themaking of a firmer bond in its cemented union upon the rubber body of the ball, than is a cloth upon both of whose surfaces a relatively heavy nap has been developed; and, in consequence, the cover is more intimately united to the body, and in this respect also a ball of greater durability is produced.

In a tennis ball as usually formedL with a by weaving the cloth for the felt cover in the manner shown in Figs. III-V or in the-manner shown in Figs, VI-VIII, andv described herein, more than two thirds (about '70%) of the total body of wool are available. Under comparative test the balls of my invention were not rejected until they had endured wear of 35% longer duration than balls covered with felt of usual character. And in all cases the covers of theV balls of my invention continued secure in adhesion to the underlying rubber and at the seams as well.

y Similarly as to a tennis ball the fabric of the invention may be applied to other carrier bodies for other particular uses-to the face of the body of a polishing roll, for example.

Inasmuch as the prolonged fulling step performed upon the already heavily teased fabric results in a product of the unique character indicated, I characterize the napping and fulling step of my procedure, and distinguish it from the fulling step of the procedure of making fabric for clothing, as felting.

I claim as my invention:

The method herein described of producing a fabric for mechanical uses which consists in weaving a woolen fabric with floats, teasing the float-bearing face of the newly woven and unfulled fabric, and in so doing raising upon the float-bearing surface a lanky, shaggy pile, then fulling the pile-faced fabric for a period of two hours and a half as a minimum, and producing a stiff and board-like web, substantially smooth on one surface, and bearing upon the opposite surface a deep and felted pile.

HARTMAN F. SCHMIDT. 

